Method and apparatus for manufacturing a material-backed engaging member for surface fastener

Abstract

A surface fastener engaging member manufacturing method includes: extruding from an extrusion nozzle a predetermined width of molten resin; introducing the molten resin into a predetermined gap between the extrusion nozzle and a die wheel to fill up coupling element molding cavities with the molten resin as the die wheel rotates in one direction; continuously molding a multiplicity of coupling elements integrally on the front surface of a continuous board-shaped base layer as the die wheel is rotated; applying a porous backing material to the base layer under pressure while the base layer is moved in response to the rotation of the die wheel; cooling the die wheel to a predetermined temperature; and positively pulling the base layer with the backing material attached thereto as cooled, from the die wheel as the molded coupling elements of the engaging section are removed off the coupling element molding cavities.

What is claimed is: 
     
       1. A method of manufacturing a continuous length of surface fastener engaging member including a base layer on the front surface of which a multiplicity of coupling elements are molded and on the back surface of which a backing material is attached, comprising the steps of: (a) extruding from an extrusion nozzle a width of molten resin;   (b) introducing the molten resin, which is extruded from the extrusion nozzle, into a gap between the extrusion nozzle and a die wheel, said gap having a constant depth extending around a partial circumference of said die wheel, which has a multiplicity of coupling element molding cavities on its circumferential surface and a cooling unit inside, to fill up the coupling element molding cavities with the molten resin as the die wheel rotates in one direction;   (c) continuously molding a multiplicity of coupling elements integrally on the front surface of a continuous board-shaped base layer as the die wheel is rotated in such a direction as to extrude the molten resin;   (d) applying a porous backing material, which is supplied separately from the molten resin and adjacently to the extrusion nozzle while being heated, to the board-shaped base layer under pressure while the board-shaped base layer is moved in response to the rotation of the die wheel;   (e) cooling the die wheel to a predetermined temperature; and   (f) positively pulling a resulting engaging member, which includes the board-shaped base layer with the backing material attached thereto as cooled, from the die wheel in the molten resin extruding direction as the molded coupling elements of the engaging member are removed off the coupling element molding cavities.   
     
     
       2. A surface-fastener engaging member manufacturing method according to claim 1, wherein the step of applying a porous backing material, which is supplied separately from the molten resin and adjacently to the extrusion nozzle while being heated, is further defined by guiding the backing material between a guide surface on the extrusion nozzle and a pressure portion facing the die wheel. 
     
     
       3. A surface fastener engaging member manufacturing method according to claim 1, wherein the step of applying a porous backing material, which is supplied separately from the molten resin and adjacently to the extrusion nozzle while being heated, is further defined by guiding the backing material within a backing material guide channel extending in the extrusion nozzle. 
     
     
       4. A surface fastener engaging member manufacturing method according to claim 1, wherein each of the coupling elements molded on the board-shaped base layer has a hook shape. 
     
     
       5. A surface fastener engaging member manufacturing method according to claim 2, wherein each of the coupling elements molded on the board-shaped base layer has a hook shape. 
     
     
       6. A surface fastener engaging member manufacturing method according to claim 3, wherein each of the coupling elements molded on the board-shaped base layer has a hook shape. 
     
     
       7. A surface fastener engaging member manufacturing method according to claim 1, wherein the porous backing material is a knitted, woven, or non-woven cloth having on one surface a multiplicity of loops. 
     
     
       8. An apparatus for manufacturing a continuous length of surface fastener engaging member including a base layer on the front surface of which a multiplicity of coupling elements are molded and on the back surface of which a backing material is attached, comprising: (a) a die wheel having a multiplicity of coupling element molding cavities on its circumferential surface and a built-in cooling means;   (b) a drive means for rotating said die wheel in one direction;   (d) an extrusion nozzle situated adjacent to and confronting said die wheel, said extrusion nozzle having inside an extrusion flow channel through which a width of molten resin is to be extruded, said extrusion nozzle shaped to provide a substantially constant depth gap around a partial circumference of said die wheel, said gap open to said flow channel, said extrusion nozzle having a backing material guide means for guiding a backing material, which is supplied separately from the molten resin, in contact with the molten resin; and   (e) coacting puller rollers situated downstream of said die wheel in its rotating direction.   
     
     
       9. A surface-fastener engaging member manufacturing apparatus according to claim 8, wherein said backing material guide means is a guide channel defined by a nozzle surface and a guide and pressure portion of said extrusion nozzle. 
     
     
       10. A surface-fastener member manufacturing apparatus according to claim 8, wherein said backing material guide means is a guide channel formed within said extrusion nozzle.